Method of making at least one suspension load beam for an actuator assembly of a disk drive

ABSTRACT

A suspension load beam for an actuator assembly of a disk drive includes a bend radius portion with a spring rate that is less than 18 Newtons per meter, a first bending mode that is greater than 3,500 Hertz, and a first torsion mode that is greater than 5,300 Hertz. The method of making this suspension load beam includes cutting a sheet of material to form a flat suspension load beam including a bend radius portion, removing material in the bend radius portion from full thickness, inspecting the bend radius portion to determine its thickness, and removing material from the bend radius portion and/or from the main body of the suspension load beam to compromise the performance difference due to thickness variation in bend radius portion.

This is a division of application Ser. No. 09/587,793 filed Jun. 6, 2000, now U.S. Pat. No. 6,532,135.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to disk drives for information storage in computer systems, and more particularly to a suspension load beam for an actuator assembly.

2. Description of the Prior Art

Most disk drive storage systems include a plurality of disks stacked onto a rotatable spindle and a corresponding number of magnetic heads that read binary digital information from the disks and write such information on them. The magnetic heads are typically mounted on sliders that are positioned over the surfaces of the disks by rotary movement of the actuator.

A voice coil motor drives the actuator; and this motor typically includes permanent magnets mounted to the base member and a wire and bobbin coil assembly mounted on the actuator. The forces generated by the interaction between the input current of the coil assembly and the magnetic field of the permanent magnets drive the actuator to various positions over the disks.

The actuator assembly norm ally includes an actuator arm pivotally mounted to the base member with a pivot bearing cartridge, or other type of pivoting mechanism known in the art, a suspension load beam secured to an end portion of the arm, and a flexure secured to an end portion of the suspension load beam. The flexure supports the magnetic heads at a distal end, including read and write elements and a slider.

As performance and resonant frequency requirements have become more and more stringent, suspension load beam designs have become more and more complex, as have the methods of forming the suspension toad beams. One design option used in making suspension load beams is the use of partial etching in certain areas of the suspension load beam. The process of partial etching, however, does not allow the requisite control to achieve close tolerances in the suspension load beam thickness. Variations as small as ±0.15 mil to ±0.25 mil in the thickness of the bend radius portion of a suspension load beam cause substantial variations in the spring rate, resonant frequencies, as well as other physical parameters of the beam. Substantial variation from the desired design parameters becomes a significant drawback in fabrication and results in low production yields.

The suspension load beam of the present invention and the method of producing it meets the most stringent performance and resonant frequency requirements. The method provides a solution to compensate the partial etched suspension load beams with loose tolerances in thickness, and it does so efficiently and inexpensively, maximizing the yield in production.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, a suspension load beam for an actuator includes a bend radius portion with a spring rate that is less than 18 Newtons per meter, a first bending mode that is greater than 3,500 Hertz, and a first torsion mode that is greater than 5,300 Hertz. The method of making this suspension load beam includes etching a sheet of material to form the full suspension load beam profile including a partially etched bend radius portion, inspecting the bend radius portion to determine its thickness, and removing more material from the bend radius portion, and/or from the main body of the suspension load beam, to obtain close tolerances for the required performance.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this invention, one should now refer to the embodiment illustrated in greater detail in the accompanying drawings and described below by way of an example of the invention. In the drawings:

FIG. 1 is a perspective view of a hard disk drive with a portion of its casing cut away to show the actuator, including an arm, a suspension swage plate, a suspension load beam of the present invention, and a flexure, and a head slider.

FIG. 2 is a sectional view taken along line 2—2 in FIG. 1;

FIG. 3 is a plan view of the bend radius portion of a suspension load beam of the present invention;

FIG. 4 is a sectional view taken along line 4—4 in FIG. 3;

FIG. 5 is an exploded perspective view of the front end of the actuator of FIG. 1, including the suspension load beam of the present invention;

FIG. 6 is a perspective view showing the front end of the actuator in an assembled form, including suspension and head slider;

FIG. 7 is a perspective view of a sheet of material with a plurality of suspension load beams cut into the sheet;

FIG. 8 is a schematic view of the inspecting step of the process of forming the suspension load beam of the present invention;

FIG. 9 is a schematic view of the material removing step of the process for optimization of bend radius profile of the present invention;

FIG. 10 is a schematic view of the step of securing a flexure to the suspension load beam, by spot welding;

FIG. 11 is a perspective view, showing a bending step of the process of the present invention;

FIG. 12 is a plain view of the bend radius portion of the suspension load beam identified as Example 1 in Table 1, incorporating the present invention;

FIG. 13 is a plain view of the bend radius portion of the suspension load beam identified as Example 2 in Table 1, incorporating the present invention;

FIG. 14 is a plain view of the bend radius portion of the suspension load beam identified as Example 3 in Table 1, incorporating the present invention; and

FIG. 15 is a plain view of the bend radius portion of the suspension load beam identified as Example 4 in Table 1, incorporating the present invention.

While the following disclosure describes the invention in connection with one embodiment, one should understand that the invention is not limited to this embodiment. Furthermore, one should understand that the drawings are not to scale and that graphic symbols, diagrammatic representatives, and fragmentary views, in part, may only illustrate the embodiment. In certain instances, the disclosure may not include details which are not necessary for an understanding of the present invention such as conventional details of fabrication and assembly.

DETAILED DESCRIPTION OF THE DRAWINGS

Turning now to the drawings and referring specifically to FIGS. 1-4, a hard disk drive apparatus H includes a base B, a cover C, one or more disks D, and an actuator assembly A having an arm 10 pivotally mounted to the base B with a pivot bearing cartridge (not shown) as at 11. A voice coil motor 12 drives the arm 10 about its pivot 11; and this motor includes permanent magnets 13 mounted to the base B and a voice coil mounted to the arm 10. The forces generated by the interaction between the magnetic field of the voice coil and those of the permanent magnets drive the actuator to various desired positions. For each disk D, the arm 10 includes an arm segment 10 a that extends outwardly of the pivot 11.

A suspension load beam 14 of the present invention has a generally elongate configuration (See FIGS. 2, 5, and 6). It generally includes a secured end portion, a suspended end portion opposite the secured end portion, and a bend radius portion between the two end portions. The suspension load beam 14 lies secured (e.g., swaged) at its secured end to an end portion of the arm segment 10 a, and it extends outwardly of the arm segment 10 a in cantilevered fashion. A base plate 15 with an integral sleeve portion 15 a secures the suspension load beam 14 to the arm segment 10 a. The sleeve portion 15 a extends through an opening 14 a at the secured end of the beam 14 and, in a press fit, into an opening 10 b at an end portion of the arm segment 10 a.

At its opposite, suspended end, the suspension load beam 14 supports a flexure member 16 which, in turn, supports a slider 17 including the magnetic heads that “read” digital information from the disk D and “write” such information on them. The flexure member 16 ties secured (as with-spot welding) to the bottom face of the suspension load beam 14 in proper alignment as defined by the openings 14 b and 14 c in the suspension load beam 14 and the corresponding openings 16 a and 16 b in the flexure member 16. (Placing the openings 14 b and 14 c in register, with the openings 16 a and 16 b, respectively, places the flexure member 17 in proper alignment with the suspension load beam 14.)

Various other features of the suspension load beam 14 help maintain the structural integrity of the beam and define physical parameters, including spring rate and various resonant frequencies (such as bending, torsion and sway). Bent edge portions on opposite sides of the suspension load beam define rails 18 and 19 that maintain the rigidity of the beam structure. An opening 14 d in the bend radius portion of the beam, as well as opening 14 e in the main body of the suspension load beam 14, also helps define the spring rate and resonant frequencies of the beam. It should be appreciated that the number of openings, their location and their shape can further influence the spring rate and resonant frequencies of the beam. Also, the thickness of the bend radius portion helps determine, among other parameters, the spring rate and resonant frequencies. Variations as small as ±0.15 mil to ±0.25 mil in thickness of the bend radius portion of the suspension load beam cause substantial variations in the spring rate, resonant frequencies. The suspension load beam of the present invention made with the following method of the present invention minimizes those variations.

The method of making the suspension load beam 14 includes providing a flat, thin sheet of material M such as non-magnetic stainless steel. Using conventional full-depth etching techniques, conventional equipment cuts one or more suspension load beams 14 from the sheet. (This etching defines the periphery of the suspension load beam 14 and the openings, i.e., 14 a-e, within the periphery. See FIG. 7.) The etching equipment also performs the following step of the method: controlled removal or controlled etching of a predetermined thickness or height of the bend radius portion of the suspension load beam 14. (See FIGS. 8 and 4.) After the controlled etching step, one or more of a variety of non-contact inspection tools (e.g., x-ray, laser, or ultrasonic equipment), inspects the bend radius portion and generates a profile matrix that identifies the areas of the bend radius portion that require further material removal (i.e., the bend radius profile modification) to compensate spring rate and major resonant frequencies within a prescribed tolerance. (See FIG. 9.) Conventional laser engraving equipment then performs this additional removal. (See FIG. 8.)

The next step in the manufacturing process involves securing (e.g., spot welding) the flexure member 16 to the suspension load beam. (See FIG. 10.) Finally, bending the edge portions to form the rails 18 and 19, the tabs 20 to allow easy attachment of wire connections, and the bend radius portion to introduce pre-loading onto the beam completes the fabrication of the beam. One may place the beam in position for securing it to the arm segment 10 a and then secure these two components by forcing the base plate 15 in place, as described in the text above.

Using the method of the present invention, suspension load beams with the following modified bend radius portions were obtained, and they had the following parameters as determined by conventional finite element analysis techniques:

TABLE 1 Suspension Bend Radius Modification - FEA Prediction Kv (N/m) B1 T1 B2 T2 Sway 1.85 + 0.15 mil 18.84 3,568 5,439 7,902 12,816 11,899 partial-etched bend radius Nominal; 16.06 3,505 5,288 7,742 12,633 11,772 t = 1.85 mil 1.85 − 0.15 mil etched 12.85 3,407 5,061 7,511 12,450 11,594 bend radius Radius modification 17.89 3,568 5,421 7,899 12,773 11,764 Example 1 (FIG. 12) t = 1.85 + 0.15 mil Radius modification 15.98 3,566 5,395 7,892 12,347 11,082 Example 2 (FIG. 13) t = 1.85 + 0.15 mil Radius modification 17.59 3,562 5,394 7,900 12,601 11,756 Example 3 (FIG. 14) t = 1.85 + 0.15 mil Radius modification 16.12 3,561 5,368 7,879 12,553 11,726 Example 4 (FIG. 15) t = 1.85 + 0.15 mil Examples 1-4 from the proceeding table are illustrated in FIGS. 12-15, respectfully. Each example, and associated figures, illustrate a small change in the bend radius profile or geometry. For these examples t is the thickness of the bend radius, Kv is the spring rate, B1 is the first bending mode, T1 is the first torsion mode, B2 is the second bending mode, and T2 is the second torsion mode.

While the above description and the drawings disclose and illustrate one embodiment, one should understand, of course, that the invention is not limited to this embodiment. Those skilled in the art to which the invention pertains may make other modifications and embodiments employing the principles of this invention, particularly upon considering forgoing teachings. Therefore, by the appended claims, the applicants intend to cover any modifications and other embodiments as incorporate those features which constitute the essential features of this invention. 

1. A method of making at least one suspension load beam for an actuator assembly of a disk drive, said method comprising the steps of: (a) providing a sheet of material; (b) cutting the sheet to form at least one flat suspension load beam of predetermined configuration with opposite end portions and a bend radius portion; (c) removing material in the bend radius portion of said at least one suspension load beam; (d) generating a profile modification matrix that identifies one or more selected parts of the bend radius portion of said at least one suspension load beam for further removal of material and; (e) removing material from said one or more selected parts of the bend radius portion of said at least one suspension load beam.
 2. The method of claim 1, wherein the cutting step includes full-depth etching to cut out the at least one suspension load beam from the sheet.
 3. The method of claim 2, wherein the cutting step includes full-depth etching to cut out one or more openings within the periphery of the at least one suspension load beam.
 4. The method of claim 1, wherein step (c) includes controlled etching of the bend radius portion of the at least one suspension load beam.
 5. The method of claim 1, wherein step (e) includes laser engraving the bend radius portion.
 6. The method of claim 1, further comprising the step of bending the at least one suspension load beam to form rails along edge portions of said at least one suspension load beam.
 7. The method of claim 1, further comprising the step of bending the forward portion of said at least one suspension load beam with a preload.
 8. The method of claim 1, further comprising the step of: (f) removing material from selected parts of said at least one suspension load beam not comprising the bend radius portion.
 9. The method of claim 8, wherein step (f) includes laser engraving said at least one suspension load beam.
 10. The method of claim 1, wherein said at least one suspension load beam comprises a plurality of suspension load beams.
 11. The method of claim 1, further comprising inspecting the bend radius portion of said at least one suspension load beam to determine the thickness of the bend radius portion.
 12. The method of claim 11, wherein the inspecting step includes using non-contact inspection instruments.
 13. A method of making a suspension load beam for an actuator assembly of a disk drive, said method comprising the steps of: (a) providing a sheet of material; (b) cutting the sheet to form a plurality of suspension load beams of predetermined configuration with opposite end portions and a bend radius portion; (c) removing material in the bend radius portion from full thickness of each suspension load beam to form multiple cavities in said bend radius portion; (d) inspecting the bend radius portion of each suspension load beam to determine the thickness of said multiple cavities of each suspension load beam; (e) removing material from selected parts of the bend radius portion of each suspension load beam. 14.The method of claim 13, wherein the cutting step includes full-depth etching to cut out the suspension load beams from the sheet.
 15. The method of claim 13, wherein the cutting step includes full-depth etching to cut out one or more openings within the periphery of each of the suspension load beams.
 16. The method of claim 13, wherein step (c) includes controlled etching of the bend radius portion of each of the suspension load beams.
 17. The method of claim 13, wherein the inspecting step includes using non-contact inspection instruments.
 18. The method of claim 13, wherein step (e) includes laser engraving the bend radius portion of each suspension load beam.
 19. The method of claim 13, further comprising the step of bending the suspension load beams to form rails along edge portions of the suspension load beams.
 20. The method of claim 13, further comprising the step of bending the forward portion of the suspension load beam with a preload.
 21. The method of claim 13, further comprising the step of: (f) removing material from selected parts of the suspension load beam.
 22. The method of claim 21, wherein step (f) includes laser engraving the suspension load beam.
 23. The method of claim 13, wherein one or more of said multiple cavities are formed at the edge of the radius portion. 